Download Aluminum-Copper Cable Presentation

Evaluation of Aluminum Cable
Presentation for IEEE OCS
September 14, 2011
Breck Booker, Southwire
Today’s Topics
Brief Overview of Southwire
In-depth Discussion on Aluminum
Characteristics
Discussion of Southwire Aluminum 600 volt
and MV Products.
Founded in 1950 by Roy Richards Sr.
We manufacture all types of wire and cable
that deliver power from the generation plant to
the residential home.
Southwire Today
Employ over 4,000 Worldwide
Annual Sales Approx. $5.5 billion
9 distribution centers in North America
Leaders in Research & Development
First to commercialize a superconductivity circuit that
feeds one of our plants
Southwire holds more than 240 patents in 40 countries
Monthly Average Copper Price
Why Market Aluminum?
COST SAVINGS: 70% of the cable cost is in
the metals.
Aluminum is code compliant, safe and reliable
With a differential of $2.00 between copper and
aluminum there is a potential for 35% - 50% savings
Honda Indiana Plant –15kv AIA and 600 volt AIA
Bloomingburg Ethanol Plant, Bloomingburg, Ohio
Met-Life Stadium (GO JETS)
Charlotte Bobcat Arena
GM 5E Spec
Lead time 7 weeks
Aluminum Product Offering
Medium voltage single conductor cable – 2kv-46kv
Multi-conductor non-armored cable – CT3-13ET and CT309ET
Interlocked armor – AL-13ET and AL-09ET
Single conductor Tray Rated – XHHW-2
Multi-conductor Tray Rated – XHHW-2/PVC
Interlocked armor – AL-01XXH
Sizes 250kcmil Aluminum and above; 3/0 copper equal
ampacity and above
Aluminum Stigma
Beverly Hills Supper Club Fire
May 28th 1977, Beverly Hills Supper
Club, Southgate KY Catches on fire, 165
fatalities. Aluminum wiring was cited as
the most probable cause. It was used on
branch circuits; receptacles, switches,
cans ext.
What Caused the Fire??
Examples of Undesirable Materials
Combination in an Electrical Connection
RESULT OF DIFFERENCES IN THERMAL EXPANSION AND CREEP OF MATERIALS :
• Rapid conductor deformation due to creep
• Loss of mechanical load and connector degradation
Definition of Thermal Expansion
and Creep
CTE: The coefficient of thermal expansion is defined as
the fractional increase in length per unit rise in
temperature. Micro inches/inch oF
Creep is the measurement of the rate of change of a
material’s dimension over a period of time when subject
to a a force at a particular temperature. Copper and
AA8000 series aluminum have similar creep rates
unlike EC 1350 which has a much higher creep rate than
copper. Micro inches per inch per hour at temperature T
and force F.
Conditions for a Reliable
Aluminum Electrical Connection
The aluminum conductor and connector
alloys must have similar “creep-properties”
to avoid loss of contact load and electrical
degradation over a long service life
NEC and UL Requirements on
Aluminum Conductors
NEC 310-14 (1987)
Aluminum conductors rated 600 volt used
inside buildings shall be made of AA-8000
series.
No aluminum grade specification on Medium
voltage Cable.
Connectors:
UL 486B
Dual rated lugs for copper or aluminum
mechanical or compression.
Aluminum Association
AA8000 Series
Alloy:
Traces of copper gives better thermal stability
Traces of iron makes it more flexible
Anneal:
Aluminum is treated with heat to removes internal
stresses in the aluminum. Less brittle
Southwire AA8176
six other series are registered with Aluminum
Association AA
Conditions for a Reliable
Aluminum Electrical Connection
Typical example of a UL Dual-Rated connection Al-Cu,
Al7-Cu or Al9-Cu.
Creep Loss % or Stress Relaxation kP
ALUMAFLEX
The creep properties of AA 8176 are comparable to
annealed copper.
Connection Preparation For
Aluminum Conductors
• Disrupt surface contaminant films with steel brush
Unused aluminum strand surfaces
before brushing.
Unused aluminum strand surfaces
after brushing.
Connection Preparation For
Aluminum Conductors
• Apply a recommended inhibitor to the conductor
• Torque the bolt or screw to levels recommended
by the manufacturer; excessive torque will
deform the conductor excessively and may lead
to loss of strands
(this applies to aluminum and copper conductor)
Copper and Aluminum
Comparison
COPPER
ALUMINUM
Heavier
500kcmil strd: 1,544lb/1,000’
Better Conductivity per size at 5 & 15kv – dc Ohms
500kcmil = .0216 ohms/1,000’
Impedance at 75C 60 Hz in Magnetic duct 5 &
15kv ohms/1,000’
4/0
: 0.0650 + j 0.0583 ; z = 0.0873
250kcmil: 0.0557 + j 0.0570 ; z = 0.0797
350kcmil: 0.0386 + j 0.0562 ; z = 0.0681
500kcmil: 0.0300 + j 0.0526 ; z = 0.0605
750kcmil: 0.0223 + j 0.0497 ; z = 0.0545
Source: IEEE 141 - 1993
Lighter – 54% lighter
750kcmil strd: 704lb/1,000’
Aluminum – 61% Conductivity of Cu – dc Ohms
500kcmil = .0354 ohms/1,000’
750kcmil = .0236 ohms/1,000’
Impedance at 75C 60 Hz in Magnetic duct 5 &
15kv ohms/1,000’
350kcmil: 0.0614 + j 0.0468 ; z = 0.0773
500kcmil: 0.0435 + j 0.0444 ; z = 0.0624
600kcmil: 0.0366 + j 0.0431 ; z = 0.0566
750kcmil: 0.0298 + j 0.0419 ; z = 0.0514
1000kcmil: 0.0233 + j 0.0414 ; z = 0.0475
Types of Strand Construction
Approximate size comparison:
3%
9%
Concentric Compressed Compact
15%
Solid
Aluminum Cable Construction
Aluminum cable is similar to copper with the exception
the conductor will be aluminum. Tape shield will
remain copper.
Tape shield always copper
Compressed Cu
Compact Al
Comparison of Copper and
Aluminum Conduit Fill, 600 Volt
Cu Size
Amps
Al Size
Amps
EMT Size
#4
85
#2
90
1 1/4
#2
115
1/0
120
1 1/2
1/0
150
3/0
155
2
2/0
175
4/0
180
2
3/0
200
250 kcmil
205
2 1/2
4/0
230
300 kcmil
230
2 1/2
250 kcmil
255
350 kcmil
250
2 1/2
350 kcmil
310
500 kcmil
310
3
400 kcmil
335
600 kcmil
340
3
500 kcmil
380
750 kcmil
385
4
600 kcmil
420
900 kcmil
430
4
Conduit Fill - Table C.1; C.1A, 2005 NEC Annex C, 4 wire plus ground
Ampacity – Table 310.16 @75C; 30C ambient.
Comparison of Copper and
Aluminum Conduit Fill, 5kv
Cu Size
Cu OD
Amps
Rigid
Size
Al Size
Al OD
Amps
Rigid Size
#2
0.76
130
3
1/0
0.84
140
3
1/0
0.87
180
3
4/0
0.98
215
3
2/0
0.91
205
3
4/0
0.98
215
3
4/0
1.02
280
3
350kcmil
1.13
305
3
250kcmil
1.07
315
3
500kcmil
1.26
380
4
350kcmil
1.18
385
4
600kcmil
1.35
385
4
500kcmil
1.30
475
4
750kcmil
1.45
490
4
750kcmil
1.49
600
5
1000kcmil
1.60
580
5
Conduit fill is based on 3 phase with equipment ground size per NEC.
All Conduit Sizes are Rigid Metal
Ampacity based on Table 310.73 and 310.74 conduit in air.
1000kcmil Al DOES NOT meet the ampacity of 750kcmil Cu.
Comparison of Copper and
Aluminum Conduit Fill, 15kv
Cu Size
Cu
OD
Amps
Rigid
Size
Al Size
Al OD
Amps
Rigid
Size
#2
.99
150
3
1/0
1.04
150
3
1/0
1.08
195
3
4/0
1.19
230
3
2/0
1.12
225
3
4/0
1.19
230
3
4/0
1.22
295
4
350kcmil
1.35
310
4
250kcmil
1.28
330
4
500kcmil
1.47
385
4
350kcmil
1.38
395
4
600kcmil
1.56
395
5
500kcmil
1.50
480
5
750kcmil
1.66
485
5
750kcmil
1.76
585
5
1000kcmil
1.89
565
6
Conduit fill is based on 3 phase with equipment ground size per NEC.
All Conduit Sizes are Metal Rigid
Ampacity based on Table 310.73 and 310.74 conduit in air.
1000kcmil Al DOES NOT meet the ampacity of 750kcmil Cu.
Flexibility
Alloying and annealing processes make AA-8176
as flexible for equivalent Ampacity copper
conductors.
NEC 312.6(B) requires the same bending space in
enclosures at terminals for equal ampacity copper
and AA-8176 conductors.
Pulling Tensions and
Minimum Bending Radius
AA 8176 aluminum has higher tensile strength to weight
ratio than equivalent copper ampacity.
Max allowable tensile for copper is 0.008 lbs/cmil and
for AA 8176 is 0.006 lbs/cmil.
Minimum bending radius for both aluminum and copper
shielded cable is 12 times the OD and 8 times the OD
for non-shielded cable.
Pulling Tensions (Cont.)
Conductor Size
Max Allowable
Tension lbs
Weight
lbs/1,000’
Max Pull Length
(ft)
0.3 coef fric
500kcmil Cu
4000 lbs
1544
8,639
750kcmil Al
4500 lbs
704
21,307
New Products
New No Lead EPR Polymer
New “Sim pull” Jacket for MV
cable
Instrumentation Cable (600V)
Ingredients of our Current
EPR Insulation ERI-3728-5
Base Filler (EPDM)
Silane
Paraffin Wax
Red Lead
Clay Filler
Zinc oxide
Polyethylene
Peroxide
Southwire buys its EPR from Electric Cable Compounds,
Inc located in Seymour Connecticut. The present EPR
compound we use is Superohm ERI-3728-5.
Ingredients of our New
EPR Insulation ERI-3748
Base Filler (EPDM)
Silane
Paraffin Wax
Red Lead
Clay Filler
Zinc oxide
Polyethylene
Peroxide
Eco Friendly Cable EFC – Dovetails with green environments,
Hospitals, schools, institutional.
Features of our New
EPR Insulation ERI-3748
No Lead
Creamy in color – Lead is what gives EPR its
reddish color
UL listed
AEIC qualified
Has wet rating just like leaded EPR
EXACT SAME Characteristics
Questions?
We want to earn your business !!!